11.6.2 Damage initiation

Product: ABAQUS/Explicit  

References

Overview

The material damage initiation capability:

  • is intended as a general capability for predicting initiation of damage in metals, including sheet, extrusion, and cast metals as well as other materials;

  • can be used in combination with the damage evolution models described in Damage evolution and element removal, Section 11.6.3;

  • allows the specification of more than one damage initiation criterion;

  • includes ductile, shear, forming limit diagram (FLD), forming limit stress diagram (FLSD), and Marciniak-Kuczynski (M-K) criteria for damage initiation;

  • can be used in conjunction with Mises plasticity, Johnson-Cook plasticity, and, with the exception of the M-K criterion, Hill and Drucker-Prager plasticity; and

  • can be used with cohesive elements in both ABAQUS/Explicit and ABAQUS/Standard to define damage initiation based on a maximum nominal stress or strain or a quadratic nominal stress or strain criterion (see Defining the constitutive response of cohesive elements using a traction-separation description, Section 18.5.6).

Damage initiation criteria for fracture of metals

Two main mechanisms can cause the fracture of a ductile metal: ductile fracture due to the nucleation, growth, and coalescence of voids; and shear fracture due to shear band localization. Based on phenomenological observations, these two mechanisms call for different forms of the criteria for the onset of damage. The functional forms provided by ABAQUS/Explicit for these criteria are discussed below. These criteria can be used in combination with the damage evolution models discussed in Damage evolution and element removal, Section 11.6.3, to model fracture of a ductile metal. (See Eroding projectile impacting eroding plate, Section 2.1.4 of the ABAQUS Example Problems Manual, for an example.)

Ductile criterion

The ductile criterion is a phenomenological model for predicting the onset of damage due to nucleation, growth, and coalescence of voids. The model assumes that the equivalent plastic strain at the onset of damage, , is a function of stress triaxiality and strain rate:

where is the stress triaxiality, is the pressure stress, is the Mises equivalent stress, and is the equivalent plastic strain rate. The criterion for damage initiation is met when the following condition is satisfied:

where is a state variable that increases monotonically with plastic deformation. At each increment during the analysis the incremental increase in is computed as

The ductile criterion can be used in conjunction with the Mises, Johnson-Cook, Hill, and Drucker-Prager plasticity models, including equation of state.

Input File Usage:           Use the following option to specify the equivalent plastic strain at the onset of damage as a tabular function of stress triaxality, strain rate, and, optionally, temperature and predefined field variables:
 
*DAMAGE INITIATION, CRITERION=DUCTILE, DEPENDENCIES=n

Shear criterion

The shear criterion is a phenomenological model for predicting the onset of damage due to shear band localization. The model assumes that the equivalent plastic strain at the onset of damage, , is a function of the shear stress ratio and strain rate:

Here is the shear stress ratio, is the maximum shear stress, and is a material parameter. The criterion for damage initiation is met when the following condition is satisfied:

where is a state variable that increases monotonically with plastic deformation proportional to the incremental change in equivalent plastic strain. At each increment during the analysis the incremental increase in is computed as

The shear criterion can be used in conjunction with the Mises, Johnson-Cook, Hill, and Drucker-Prager plasticity models, including equation of state.

Input File Usage:           Use the following option to specify and to specify the equivalent plastic strain at the onset of damage as a tabular function of the shear stress ratio, strain rate, and, optionally, temperature and predefined field variables:
 
*DAMAGE INITIATION, CRITERION=SHEAR, KS=, DEPENDENCIES=n

Damage initiation criteria for sheet metal instability

Necking instability plays a determining factor in sheet metal forming processes: the size of the local neck region is typically of the order of the thickness of the sheet, and local necks can rapidly lead to fracture. Localized necking cannot be modeled with traditional shell elements used in sheet metal forming simulations because the size of the neck is of the order of the thickness of the element. ABAQUS/Explicit supports three criteria for predicting the onset of necking instability in sheet metals: forming limit diagram (FLD), forming limit stress diagram (FLSD), and Marciniak-Kuczynski (M-K) criteria. These criteria apply only to elements with a plane stress formulation (plane stress, shell, continuum shell, and membrane elements); ABAQUS/Explicit ignores these criteria for other elements. The initiation criteria for necking instability can be used in combination with the damage evolution models discussed in Damage evolution and element removal, Section 11.6.3, to account for the damage induced by necking.

Strain-based forming limit diagrams (FLDs) are known to be dependent on the strain path. Changes in the deformation mode (i.e., equibiaxial loading followed by uniaxial tensile strain) may result in major modifications in the level of the limit strains. Therefore, the FLD damage initiation criterion should be used with care if the strain paths in the analysis are nonlinear. In practical industrial applications, significant changes in the strain path may be induced by multi-step forming operations, complex geometry of the tooling, and interface friction, among other factors. For problems with highly nonlinear strain paths ABAQUS/Explicit offers two additional damage initiation criteria: the forming limit stress diagram (FLSD) criterion, which is minimally affected by changes in strain paths, and the Marciniak-Kuczynski (M-K) criterion, which can predict the forming limits numerically for arbitrary loading paths.

Forming limit diagram (FLD) criterion

The forming limit diagram (FLD) is a useful concept introduced by Keeler and Backofen (1964) to determine the amount of deformation that a material can withstand prior to the onset of necking instability. The maximum strains that a sheet material can sustain prior to the onset of necking are referred to as the forming limit strains. A FLD is a plot of the forming limit strains in the space of principal (in-plane) logarithmic strains. In the discussion that follows major and minor limit strains refer to the maximum and minimum values of the in-plane principal limit strains, respectively. The major limit strain is usually represented on the vertical axis and the minor strain on the horizontal axis, as illustrated in Figure 11.6.2–1.

Figure 11.6.2–1 Forming limit diagram (FLD).

The line connecting the states at which deformation becomes unstable is referred to as the forming limit curve (FLC). The FLC gives a sense of the formability of a sheet of material. Strains computed numerically by ABAQUS/Explicit can be compared to a FLC to determine the feasibility of the forming process under analysis.

The FLD damage initiation criterion requires the specification of the FLC in tabular form by giving the major principal strain at damage initiation as a tabular function of the minor principal strain and, optionally, temperature and predefined field variables, . The damage initiation criterion for the FLD is given by the condition , where the variable is a function of the current deformation state and is defined as the ratio of the current major principal strain, , to the major limit strain on the FLC evaluated at the current values of the minor principal strain, ; temperature, ; and predefined field variables, :

For example, for the deformation state given by point A in Figure 11.6.2–1 the damage initiation criterion is evaluated as

If the value of the minor strain lies outside the range of the specified tabular values, ABAQUS/Explicit will extrapolate the value of the major limit strain on the FLC by assuming that the slope at the endpoint of the curve remains constant. Extrapolation with respect to temperature and field variables follows the standard conventions: the property is assumed to be constant outside the specified range of temperature and field variables (see Material data definition, Section 9.1.2).

Experimentally, FLDs are measured under conditions of biaxial stretching of a sheet, without bending effects. Under bending loading, however, most materials can achieve limit strains that are much greater than those on the FLC. To avoid the prediction of early failure under bending deformation, ABAQUS/Explicit evaluates the FLD criterion using the strains at the midplane through the thickness of the element. For composite shells with several layers the criterion is evaluated at the midplane of each layer for which a FLD curve has been specified, which ensures that only biaxial stretching effects are taken into account. Therefore, the FLD criterion is not suitable for modeling failure under bending loading; other failure models (such as ductile and shear failure) are more appropriate for such loading. Once the FLD damage initiation criterion is met, the evolution of damage is driven independently at each material point through the thickness of the element based on the local deformation at that point. Thus, although bending effects do not affect the evaluation of the FLD criterion, they may affect the rate of evolution of damage.

Input File Usage:           Use the following option to specify the limit major strain as a tabular function of minor strain:
 
*DAMAGE INITIATION, CRITERION=FLD

Forming limit stress diagram (FLSD) criterion

When strain-based FLCs are converted into stress-based FLCs, the resulting stress-based curves have been shown to be minimally affected by changes to the strain path (Stoughton, 2000); that is, different strain-based FLCs, corresponding to different strain paths, are mapped onto a single stress-based FLC. This property makes forming limit stress diagrams (FLSDs) an attractive alternative to FLDs for the prediction of necking instability under arbitrary loading. A FLSD is the stress counterpart of the FLD, with the major and minor principal in-plane stresses corresponding to the onset of necking localization plotted on the vertical and horizontal axes, respectively.

In ABAQUS/Explicit the FLSD damage initiation criterion requires the specification of the major principal in-plane stress at damage initiation as a tabular function of the minor principal in-plane stress and, optionally, temperature and predefined field variables, . The damage initiation criterion for the FLSD is met when the condition is satisfied, where the variable is a function of the current stress state and is defined as the ratio of the current major principal stress, , to the major stress on the FLSD evaluated at the current values of minor stress, ; temperature, ; and predefined field variables, :

If the value of the minor stress lies outside the range of specified tabular values, ABAQUS/Explicit will extrapolate the value of the major limit stress assuming that the slope at the endpoints of the curve remains constant. Extrapolation with respect to temperature and field variables follows the standard conventions: the property is assumed to be constant outside the specified range of temperature and field variables (see Material data definition, Section 9.1.2).

For reasons similar to those discussed earlier for the FLD criterion, ABAQUS/Explicit evaluates the FLSD criterion using the stresses averaged through the thickness of the element (or the layer, in the case of composite shells with several layers), ignoring bending effects. Therefore, the FLSD criterion cannot be used to model failure under bending loading; other failure models (such as ductile and shear failure) are more suitable for such loading. Once the FLSD damage initiation criterion is met, the evolution of damage is driven independently at each material point through the thickness of the element based on the local deformation at that point. Thus, although bending effects do not affect the evaluation of the FLSD criterion, they may affect the rate of evolution of damage.

Input File Usage:           Use the following option to specify the limit major stress as a tabular function of minor stress:
 
*DAMAGE INITIATION, CRITERION=FLSD

Marciniak-Kuczynski (M-K) criterion

Another approach available in ABAQUS/Explicit for accurately predicting the forming limits for arbitrary loading paths is based on the localization analysis proposed by Marciniak and Kuczynski (1967). The approach can be used with the Mises and Johnson-Cook plasticity models, including kinematic hardening. In M-K analysis, virtual thickness imperfections are introduced as grooves simulating preexisting defects in an otherwise uniform sheet material. The deformation field is computed inside each groove as a result of the applied loading outside the groove. Necking is considered to occur when the ratio of the deformation in the groove relative to the nominal deformation (outside the groove) is greater than a critical value.

Figure 11.6.2–2 shows schematically the geometry of the groove considered for M-K analysis. In the figure denotes the nominal region in the shell element outside the imperfection, and denotes the weak groove region. The initial thickness of the imperfection relative to the nominal thickness is given by the ratio , with the subscript 0 denoting quantities in the initial, strain-free state. The groove is oriented at a zero angle with respect to the 1-direction of the local material orientation.

Figure 11.6.2–2 Imperfection model for the M-K analysis.

ABAQUS/Explicit allows the specification of an anisotropic distribution of thickness imperfections as a function of angle with respect to the local material orientation, . ABAQUS/Explicit first solves for the stress-strain field in the nominal area ignoring the presence of imperfections; then it considers the effect of each groove alone. The deformation field inside each groove is computed by enforcing the strain compatibility condition

and the force equilibrium equations

The subscripts and refer to the directions normal and tangential to the groove. In the above equilibrium equations and are forces per unit width in the -direction.

The onset of necking instability is assumed to occur when the ratio of the rate of deformation inside a groove relative to the rate of deformation if no groove were present is greater than a critical value. In addition, it may not be possible to find a solution that satisfies equilibrium and compatibility conditions once localization initiates at a particular groove; consequently, failure to find a converged solution is also an indicator of the onset of localized necking. For the evaluation of the damage initiation criterion ABAQUS/Explicit uses the following measures of deformation severity:

These deformation severity factors are evaluated on each of the specified groove directions and compared with the critical values. (The evaluation is performed only if the incremental deformation is primarily plastic; the M-K criterion will not predict damage initiation if the deformation increment is elastic.) The most unfavorable groove direction is used for the evaluation of the damage initiation criterion, which is given as

where , , and are the critical values of the deformation severity indices. Damage initiation occurs when or when a converged solution to the equilibrium and compatibility equations cannot be found. By default, ABAQUS/Explicit assumes ; you can specify different values. If one of these parameters is set equal to zero, its corresponding deformation severity factor is not included in the evaluation of the damage initiation criterion. If all of these parameters are set equal to zero, the M-K criterion is based solely on nonconvergence of the equilibrium and compatibility equations.

You must specify the fraction, , equal to the initial thickness at the virtual imperfection divided by the nominal thickness (see Figure 11.6.2–2), as well as the number of imperfections to be used for the evaluation of the M-K damage initiation criterion. It is assumed that these directions are equally spaced angularly. By default, ABAQUS/Explicit uses four imperfections located at 0°, 45°, 90°, and 135° with respect to the local 1-direction of the material. The initial imperfection size can be defined as a tabular function of angular direction, ; this allows the modeling of an anisotropic distribution of flaws in the material. ABAQUS/Explicit will use this table to evaluate the thickness of each of the imperfections that will be used for the evaluation of the M-K analysis method. In addition, the initial imperfection size can also be a function of initial temperature and field variables; this allows defining a nonuniform spatial distribution of imperfections. ABAQUS/Explicit will compute the initial imperfection size based on the values of temperature and field variables at the beginning of the analysis. The initial size of the imperfection remains a constant property during the rest of the analysis.

A general recommendation is to choose the value of such that the forming limit predicted numerically for uniaxial strain loading conditions () matches the experimental result.

The virtual grooves are introduced to evaluate the onset of necking instability; they do not influence the results in the underlying element. Once the criterion for necking instability is met, the material properties in the element are degraded according to the specified damage evolution law.

Input File Usage:           Use the following option to specify the initial imperfection thickness relative to the nominal thickness as a tabular function of the angle with respect to the 1-direction of the local material orientation and, optionally, initial temperature and field variables:
 
*DAMAGE INITIATION, CRITERION=MK, DEPENDENCIES=n

Use the following option to specify critical deformation severity factors:

*DAMAGE INITIATION, CRITERION=MK, FEQ=, FNN=,
 FNT=

Performance considerations for the M-K criterion

There can be a substantial increase in the overall computational cost when the M-K criterion is used. For example, the cost of processing a shell element with three section points through the thickness and four imperfections, which is the default for the M-K criterion, increases by approximately a factor of 2 compared to the cost without the M-K criterion. You can mitigate the cost of evaluating this damage initiation criterion by reducing the number of flaw directions considered or by increasing the number of increments between M-K computations, as explained below. Of course, the effect on the overall analysis cost depends on the fraction of the elements in the model that use this damage initiation criterion. The computational cost per element with an M-K criterion increases by approximately a factor of

where is the number of imperfections specified for the evaluation of the M-K criterion and is the frequency, in number of increments, at which the M-K computations are performed. The coefficient of in the above formula gives a reasonable estimate of the cost increase in most cases, but the actual cost increase may vary from this estimate. By default, ABAQUS/Explicit performs the M-K computations on each imperfection at each time increment, . Care must be taken to ensure that the M-K computations are performed frequently enough to ensure the accurate integration of the deformation field on each imperfection.

Input File Usage:           Use the following option to specify the number of imperfections and frequency of the M-K analysis:
 
*DAMAGE INITIATION, CRITERION=MK,
 NUMBER IMPERFECTIONS=, FREQUENCY= 

Elements

The damage initiation criteria can be used with any elements in ABAQUS/Explicit that include mechanical behavior (elements that have displacement degrees of freedom).

The models for sheet metal necking instability (FLD, FLSD, and M-K) are available only with elements that include mechanical behavior and use a plane stress formulation (i.e., plane stress, shell, continuum shell, and membrane elements).

Output

In addition to the standard output identifiers available in ABAQUS/Explicit (ABAQUS/Explicit output variable identifiers, Section 4.2.2), the following variables have special meaning when a damage initiation criterion is specified:

DMICRT

All damage initiation criteria components.

DUCTCRT

Ductile failure criterion, .

SHRCRT

Shear failure criterion, .

FLDCRT

Maximum value of the FLD damage initiation criterion, , during the analysis.

FLSDCRT

Maximum value of the FLSD damage initiation criterion, , during the analysis.

MKCRT

Marciniak-Kuczynski failure criterion, .


A value of 1 or greater for output variables associated with a damage initiation criterion indicates that the criterion has been met. ABAQUS/Explicit will limit the maximum value of the output variable to 1 if a damage evolution law has been prescribed for that criterion (see Damage evolution and element removal, Section 11.6.3). However, if no damage evolution is specified, the criterion for damage initiation will continue to be computed beyond the point of damage initiation; in this case the output variable can take values greater than 1, indicating by how much the initiation criterion has been exceeded.

Additional references